Process for preparing composite molded articles by multicomponent injection molding

a composite molded and multi-component technology, applied in the direction of manufacturing tools, other domestic articles, transportation and packaging, etc., can solve the problems of complex tools, long cycle time, and damage to the structure of the first plastic part,

Inactive Publication Date: 2002-08-15
LANXESS DEUTDCHLAND GMBH
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0006] The object of the present invention is accordingly to provide a process that avoids the aforedescribed disadvantages of the known processes, and at the same time allows for the formation of a specific interlocking connection between the various plastics parts composed of different plastic materials.
[0012] (a) providing a multicomponent injection molding tool (20) having at least two separate melt flow-way systems and at least two cavities in which each of the first and second thermoplastic parts are separately formed, each of said cavities being in separate communication with each of said separate melt flow-way systems;
[0032] The composite articles produced by the process of the present invention may serve as structural parts for use in the vehicle construction sector, e.g. as seat structures, door units, front end parts, door sills with a combination of elastic and rigid plastics materials, entry strips, radiators, or as housings for domestic appliances, small electrical devices and office equipment.

Problems solved by technology

A disadvantage of such known generic processes is that they typically have a long cycle time.
One has to wait for the first plastics component to cool down since otherwise the structure of the first plastics part would be damaged.
In addition, such processes typically require the use of complicated tools having special slide bars.

Method used

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  • Process for preparing composite molded articles by multicomponent injection molding
  • Process for preparing composite molded articles by multicomponent injection molding
  • Process for preparing composite molded articles by multicomponent injection molding

Examples

Experimental program
Comparison scheme
Effect test

example 1

[0034] FIG. 1 shows the support structure for the front unit of a vehicle consisting of the base body 1 of sheet steel, two headlamp supports 2,3 of an unreinforced amorphous thermoplastics material (polycarbonate -ABS mixture), a radiator unit support 4 of a glass fibre-reinforced thermoplastics material (polyamide), a rib structure 5 of a glass fibre-reinforced thermoplastics material (polyamide) and a screen 6 of a glass fibre-reinforced thermoplastics material (polyamide).

[0035] FIG. 2 shows a section through the base body 1, the screen 6, the rib structure 5 and the headlamp support 3. The rib structure 5 and the screen 6 form a unit and are joined to the base body 1. The headlamp support 3 is separated from the rib structure 5 via the sealing surfaces 7,8 on the base body 1, but is rigidly joined in an interlocking manner to the base body 1 via the edge 9 encapsulated by injection molding and the sprueless injection molded part 10. The base part 1 is shown cut away in the midd...

example 2

[0040] FIG. 4 shows a variant of the structural part according to FIG. 1 in the same section as in FIG. 3, though the edge encapsulated by injection molding 16 has a Z-shape, with the result that the radiator unit support is rigidly joined to the base body 1, though movement of the said radiator unit support in the longitudinal direction of the edge 16 is permitted.

example 3

[0041] A shell-shaped base body 1, preferably of deep-drawn steel sheet, aluminium sheet or also plastics material, is automatically placed in a contour-tight manner via a robot in an open injection molding tool 20, preferably on the injection side 21.

[0042] By the closure of the injection molding tool (FIG. 5) the base body 1 is accommodated in a largely interlocking manner due to the contour surface 24 of the injection side and due to contour surfaces 25 of the closure side, as far as the hollow spaces 22, 23 for the plastics materials A and B. In this way sealing surfaces 7, 8 (cf. FIG. 1); 11, 12 (FIGS. 3 and 6); 14, 15 (FIGS. 3 and 4) etc., can be formed, with the result that the individual plastics materials A and B can flow during the injection process absolutely separately into the provided hollow spaces 22,23.

[0043] After the closure of the injection molding tool the adjoining injection molding units I and II simultaneously inject the respective amounts of plastics material...

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Abstract

A process for producing a composite molded article is described. The composite molded article includes: (i) at least one base body (1) having a contoured surface; (ii) at least one first thermoplastic part (4, 5, 6); and (iii) at least one second thermoplastic part (2, 3), each of the first and second thermoplastic parts being joined to the base body. The process includes, (a) providing a multicomponent injection molding tool (20) having at least two separate melt flow-way systems and at least two cavities in which each of the first and second thermoplastic parts are separately formed, each of the cavities are in separate communication with each of the separate melt flow-way systems. The base body is placed into the molding tool in a second step (b). The cavities of the mold are separated from each other by a combination of the contoured surface of the base body and sealing edges of the molding tool that abut the contoured surface of the base body. In a third step (c), a thermoplastic material is injected simultaneously into each of the cavities by means of the separate melt flow-way systems. The first and second thermoplastic parts (ii) and (iii) each become joined to the base body (i) during injection molding step (c). In a final step (d), the composite molded article is removed from the molding tool.

Description

CROSS REFERENCE TO RELATED PATENT APPLICATION[0001] The present patent application claims the right of priority under 35 U.S.C. .sctn.119 (a)-(d) of German Patent Application No. 101 06 458.6, filed Feb. 13, 2001.[0002] The present invention relates to a process for the production of composite molded articles comprising at least one base body, at least one first thermoplastic part and at least one second thermoplastic part that are concurrently formed and joined to the base body by injection molding. The first and second plastic parts may be composed of different plastic materials. The base body is first placed in a multicomponent injection molding tool having at least two separate melt flow-way systems (melt injection passages or ports) and at least two cavities for each of the first second plastic parts. The plastic materials from which the first and second plastic parts are formed, are then concurrently injected into the cavities, followed by removing the composite part from the ...

Claims

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Application Information

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IPC IPC(8): B29C45/14B29C45/16B62D29/04
CPCB29C45/14467B29C45/1671B29L2031/3002B62D29/041
InventorGOLDBACH, HUBERT
OwnerLANXESS DEUTDCHLAND GMBH